Polymer coated optical fiber

ABSTRACT

Coated optical fibers and uses of such fibers as sensors in high temperature and/or high pressure environments. The coated optical fiber has improved sensing properties at elevated pressure and/or temperature, such as enhanced acoustic sensitivity and/or a reduced loss in acoustic sensitivity. The use of the coated optical fibers in various sensing applications that require operation under elevated pressure and/or temperature, such as, acoustic sensors for various geological, security, military, aerospace, marine, and oil and gas applications are also provided.

CROSS REFERENCE TO RELATED APPLICATIONS

This is a Continuation of U.S. patent application Ser. No. 15/120,434,filed Aug. 19, 2016, which is the U.S. National Stage of InternationalApplication No. PCT/US2015/016664, filed Feb. 19, 2015, which in turnclaims the benefit of and priority to U.S. Provisional Application No.61/941,958, filed Feb. 19, 2014, all of which are hereby incorporated byreference.

FIELD OF THE INVENTION

The present invention relates to the field of fiber optics and, inparticular, to a polymer coated optical fiber suitable for use as asensor in high temperature and/or high pressure operating conditions.

BACKGROUND OF THE INVENTION

Optical fibers find widespread use in acoustic sensors (Kirkendall &Dandridge, 2004, J. Phys. D: Appl. Phys. 37:R197-R216). Polymericcoatings over optical fibers are known to increase the acousticsensitivity of the fiber (Hughes & Jarzynski, 1980, Applied Optics,19(1):98-107; Giallorenzi et al., 1982, IEEE J Quantum Engineering,QE18, pp 626-665). Further enhancement of sensitivity has beendemonstrated through the use of air-included polymer (AIP) coatings(Cole et al., 2002, 15^(th) Optical Fiber Sensors Conf. (Portland Oreg.)vol 15 IEEE Catalog 02EX533). AIP coatings, however, include air bubblesthat collapse as operating pressures increase which significantlyreduces the sensitivity enhancement. AIP coatings, therefore, are notsuitable for high pressure applications.

Many fiber optic based sensors are required for applications that entailhigh temperature and/or high pressure operating conditions, such asdownhole sensors in the oil and gas industry, deep water seismicexploration, nuclear reactor performance and safety monitoring,earthquake monitoring and localization, earthquake precursor alarmsystems, detection of nuclear weapon test and/or treaty violations.

Commercially available electrical downhole sensor systems (without useof cooling or temperature isolation devices) are limited to use indownhole applications at temperatures of 110° C. or below. Varioussolutions for permitting use of optical fibers at high temperatures havebeen proposed, including commercially available coated and/or jacketedfibers (for example, from OFS (Specialty Photonics) and FiberguideIndustries).

U.S. Pat. No. 6,915,056 describes a buffer tube for optical fibers thatis easily strippable and will not be subject to melting or sticking toother buffer tubes during the cable manufacturing process. The buffertubes comprise a blend of at least 40% by weight of a copolyetherelastomer, at least 10% by weight of an amorphous thermoplastic polymerand at least 10% by weight of a rubbery modifier. Preferred copolyetherelastomers include Hytrel® thermoplastic elastomers, particularlyHytrel® grade G5544.

U.S. patent application Ser. No. 13/414,157 (US 2012/0227504) providesan alternative to coated fibers in the form of a sensor array suitablefor underwater use that comprises a cladded core, a polymer layerdisposed on the cladded core, an optical fiber wound around the polymerlayer and a second polymer layer disposed over the initial polymer layerand the optical fiber. Exemplary polymers described are polyetherurethanes and polyester urethanes.

This background information is provided for the purpose of making knowninformation believed by the applicant to be of possible relevance to thepresent invention. No admission is necessarily intended, nor should beconstrued, that any of the preceding information constitutes prior artagainst the present invention.

SUMMARY OF THE INVENTION

The present invention relates generally to polymer coated optical fibersand sensor systems comprising same. One aspect of the invention relatesto a coated optical fiber comprising: an optical fiber, and a polymericcoating over the optical fiber, the polymeric coating comprising athermoset, thermoplastic or UV cured elastomer having a Poisson's Ratioof between about 0.350 and about 0.4995, and a shear modulus of betweenabout 20 psi and about 2900 psi.

Another aspect of the invention relates to an acoustic sensor systemcomprising a coated optical fiber as described above.

Another aspect of the invention relates to a method of producing acoated optical fiber having an increased Sensitivity Scale Factor ofbetween about 5 dB and about 60 dB over bare fiber, the methodcomprising coating an optical fiber with a thermoset or thermoplasticelastomer, the thermoset or thermoplastic elastomer having a Poisson'sRatio of between about 0.350 and about 0.4995, and a shear modulus ofbetween about 20 psi and about 2900 psi.

Another aspect of the invention relates to a system for detectingacoustic changes in a channel, the system comprising a coated opticalfiber as described above.

Another aspect of the invention relates to a system for detectingacoustic changes in a channel, the system comprising at least one coatedoptical fiber, an interrogator optically coupled to the coated opticalfiber and a signal processing device in communication with theinterrogator, wherein the coated optical fiber comprises an opticalfiber having a polymeric coating, the polymeric coating comprising athermoset, thermoplastic or UV cured elastomer having a Poisson's Ratioof between about 0.350 and about 0.4995, and a shear modulus of betweenabout 20 psi and about 2900 psi.

BRIEF DESCRIPTION OF THE DRAWINGS

These and other features of the invention will become more apparent inthe following detailed description in which reference is made to theappended drawings.

FIG. 1A-D present schematic diagrams of a sensor system comprisingpolymer coated optical fiber that includes Fiber Bragg Gratings (FBGs)in one embodiment of the invention.

FIG. 2 is a schematic diagram of a sensor system for downholeapplications comprising polymer coated optical fiber in one embodimentof the invention.

FIG. 3 shows schematic cross-sections of (a) an exemplary coated opticalfiber having a single primary coating, and (b) an exemplary coatedoptical fiber having a primary and secondary coating, under a coating ofthermoplastic, thermoset or UV cured elastomer.

FIG. 4 presents a comparison of scale factors for optical fibers coatedwith Hytrel® 3078 (H1) and UV-cured urethane (P1) (test data) vs. barefiber (calculated).

DETAILED DESCRIPTION OF THE INVENTION

The present invention relates generally to coated optical fibers anduses of such fibers as sensors in high temperature and/or high pressureoperating environments. Certain characteristics are defined herein thatallow selection of a suitable polymer, such as a thermoset,thermoplastic or UV cured elastomer that, when used to coat an opticalfiber, will impart on the fiber improved sensing properties at elevatedpressure and/or temperature. In certain embodiments, the definedcharacteristics include Poisson's Ratio and one or more elastic moduli,such as shear modulus, Young's modulus or bulk modulus. In certainembodiments, the defined characteristics include Poisson's Ratio andshear modulus. In some embodiments, the defined characteristics includePoisson's Ratio and shear modulus, Young's modulus and/or bulk modulus.

In certain embodiments, the enhanced sensing properties comprise anenhanced acoustic sensitivity and/or a reduced loss in acousticsensitivity. The improved acoustic sensing properties of the coatedoptical fibers allows for their use in various sensing applications thatrequire operation under elevated pressure and/or temperature, including,but not limited to, acoustic sensors for various geological, security,military, aerospace, marine, and oil and gas applications.

In certain embodiments, the enhanced sensing properties compriseimproved vibration sensitivity such that the polymer coated fibers mayfind use as inertial sensors, such as accelerometers and/or velocitysensors. In some embodiments, the enhanced sensing properties allow foruse of the polymer coated optical fibers as sensors to measuretemperature and pressure as a function of well depth.

In certain embodiments, the enhanced sensing properties comprise stableor enhanced thermal expansion coefficient such that the polymer coatedfibers may find use as temperature sensors to provide an importantmeasurement in high temperature well environments.

Definitions

Unless defined otherwise, all technical and scientific terms used hereinhave the same meaning as commonly understood by one of ordinary skill inthe art to which this invention belongs.

As used herein, the term “about” refers to an approximately +/−10%variation from a given value. It is to be understood that such avariation is always included in any given value provided herein, whetheror not it is specifically referred to.

The term “plurality” as used herein means more than one, for example,two or more, three or more, four or more, and the like.

The use of the word “a” or “an” when used herein in conjunction with theterm “comprising” may mean “one,” but it is also consistent with themeaning of “one or more,” “at least one” and “one or more than one.”

As used herein, the terms “comprising,” “having,” “including” and“containing,” and grammatical variations thereof, are inclusive oropen-ended and do not exclude additional, unrecited elements and/ormethod steps. The term “consisting essentially of” when used herein inconnection with a composition, use or method, denotes that additionalelements and/or method steps may be present, but that these additions donot materially affect the manner in which the recited composition,method or use functions. The term “consisting of” when used herein inconnection with a composition, use or method, excludes the presence ofadditional elements and/or method steps. A composition, use or methoddescribed herein as comprising certain elements and/or steps may also,in certain embodiments consist essentially of those elements and/orsteps, and in other embodiments consist of those elements and/or steps,whether or not these embodiments are specifically referred to.

The abbreviation “um” used herein denotes micrometers.

Coated Optical Fibers

In a broad aspect, the coated optical fiber comprises an optical fiberhaving a polymeric coating having defined characteristics. In certainembodiments, the polymeric coating comprises thermoset, thermoplastic orUV cured elastomer. In some embodiments, the polymeric coating comprisesa thermoset or thermoplastic elastomer.

Optical fibers typically include a transparent core surrounded by atransparent cladding material with a lower index of refraction. Light iskept in the core by total internal reflection, allowing the fiber to actas a waveguide. The term “cladded core” is used herein to describe thetransparent core and cladding material typically comprised by opticalfibers. Accordingly, in certain embodiments, the coated optical fibercomprises an optical fiber having a cladded core and a polymeric coatingover the cladded core.

The optical fiber may be a custom made or commercially available opticalfiber. Both glass and plastic optical fibers are contemplated in certainembodiments. Various glass and plastic optical fibers are commerciallyavailable, for example, from manufacturers such as Corning OpticalFibers (New York), Fibercore Limited (UK), Draka Communications(Prysmian Group—Milan, Italy).

In certain embodiments, the optical fiber is a quartz glass (amorphousSiO₂) fiber. The glass optical fiber may optionally be doped with a rareearth compound, such as germanium, praseodymium, or erbium oxides. Bothsingle mode and multimode optical fibers are contemplated in certainembodiments. Exemplary, non-limiting, optical fibers include ClearCurve™fibers (bend insensitive), SMF28 series single mode fibers such asSMF-28 ULL fibers or SMF-28e fibers, InfiniCor® series multimode fibers,and various fibers available from Fibercore Limited (UK).

Typically, commercially available optical fibers will include a primarycoating. In certain embodiments, optical fibers having an acrylate orpolyimide primary coating are employed with the polymer coating beingapplied over the primary coating. Preferably the primary coating will bestable at temperatures up to at least 150° C. In some embodimentsrelating to high temperature applications, the primary coating may bestable at temperatures up to at least about 320° C. Polyimide primarycoatings are particularly suitable for high temperature applications.High temperature acrylates are also available. In certain embodiments,the fiber may include a secondary coating of acrylate or polyimide withthe polymer coating being applied over the secondary coating. Forexample, the optical fiber may include a primary coating of softacrylate and a secondary coating of hard acrylate. Optical fiberscomprising a primary and optional secondary coating as described aboveare available from a number of commercial sources including, forexample, Fibercore Limited (UK), Draka Communications (PrysmianGroup—Milan, Italy).

In certain embodiments, the use of pure silica or silica clad opticalfibers is contemplated.

In certain embodiments, the optical fiber will have a diameter ofbetween about 50 um and about 200 um, including any primary andsecondary coatings. In some embodiments, optical fibers with a diameterof at least about 50 um, 60 um, 70 um or 80 um, or any amounttherebetween are employed. Upper limits for the diameter of the opticalfiber in various embodiments may be about 200 um, 150 um, 140 um, 130 umor 125 um, or any amount therebetween. In some embodiments, the diameterof the optical fiber may be between about 50 um and about 150 um,between about 50 um and about 140 um, between about 50 um and about 130um, between about 50 um and about 125 um, between about 60 um and about150 um, between about 70 um and about 150 um, or between about 80 um andabout 150 um.

FIG. 3 provides schematic cross-sections of two exemplary embodiments ofa coated optical fiber. FIG. 3(a) shows a coated optical fibre 300having a cladded core 306, a primary coating 302 of acrylate orpolyimide and a thermoset or thermoplastic elastomer coating 304. Inthis specific embodiment, the cladded core 306 may have a diameter ofabout 80 um and with the primary coating 302 has an outside diameter ofabout 140 um. A thermoset, thermoplastic or UV cured elastomer coating304 is applied, for example by extrusion, over the primary coating 302to a final diameter within the ranges described herein, for example,about 1500 um.

FIG. 3(b) shows a coated optical fibre 320 having a cladded core 326, aprimary coating 322 of soft acrylate, a secondary coating of hardacrylate 328 and a thermoset, thermoplastic or UV cured elastomercoating 324. In this specific embodiment, the cladded core 326 may havea diameter of about 80 um. A thermoset, thermoplastic or UV curedelastomer coating 324 is extruded over the primary and secondarycoatings 322, 328 to a final diameter within the ranges describedherein, for example, between about 900 nm and about 1500 um.

In certain embodiments, the optical fiber comprises Fiber Bragg'sGratings (FBGs). The FBGs may be written into the optical fiber orspliced into the optical fiber at specific locations as is known in theart. One skilled in the art will appreciate that an FBG is a type ofdistributed Bragg reflector constructed in a short section of opticalfiber that reflects particular wavelengths of light and transmits allothers. Groups of the FBGs may be located along the length of the fiber.Adjacent pairs of FBGs form a series of interferometers that may beinterrogated with a Time Division Multiplexing demodulator or similardevice.

The polymeric coating is applied over the optical fiber and optionalprimary and secondary coatings. The polymeric coating has certaindefined characteristics allowing for increased sensitivity or reducedloss in sensitivity at elevated temperature and/or pressure, for exampleincreased or reduced loss in acoustic sensitivity. Elevated temperatureas used herein in this context refers to a temperature above about 100°C. In certain embodiments, an elevated temperature may refer to atemperature above about 150° C., above about 200° C., or above about250° C. Elevated temperature ranges may be, for example, between about100° C. and about 300° C., between about 150° C. and about 300° C.,between about 200° C. and about 300° C., or between about 250° C. andabout 300° C. Elevated pressure as used herein refers to a pressureabove atmospheric pressure. In certain embodiments, elevated pressuremay refer to a pressure up to about 30,000 psig, for example, up toabout 20,000 psig, or up to about 10,000 psig.

In certain embodiments, the polymeric coating comprises a thermoset,thermoplastic or UV cured elastomer having defined characteristics thatinclude Poisson's Ratio and one or more elastic moduli, such as shearmodulus, Young's modulus or bulk modulus. One skilled in the art willappreciate that as shear modulus, Young's modulus or bulk modulus areall elastic moduli, these characteristics of the polymer areinterrelated and that while certain polymers are defined herein by theirshear modulus, they may alternatively be characterized by defining theirYoung's modulus and/or bulk modulus.

In certain embodiments, the polymeric coating comprises a thermoset,thermoplastic or UV cured elastomer having defined characteristics thatinclude Poisson's Ratio and shear modulus.

In certain embodiments, the polymeric coating comprises a thermoset,thermoplastic or UV cured elastomer having a Poisson's Ratio of betweenabout 0.350 and about 0.4995, and a shear modulus of between about 20psi and about 2900 psi. In certain embodiments, the polymeric coatingcomprises a thermoset, thermoplastic or UV cured elastomer having aPoisson's Ratio of between about 0.455 and about 0.495, between about0.455 and about 0.490, between about 0.460 and about 0.495, betweenabout 0.465 and about 0.495, between about 0.450 and about 0.485,between about 0.450 and about 0.480, between about 0.455 and about0.485, or between about 0.455 and about 0.480. In certain embodiments,the polymeric coating comprises a thermoset, thermoplastic or UV curedelastomer having a Poisson's Ratio of between about 0.460 and about0.480. In some embodiments, the polymeric coating comprises a thermoset,thermoplastic or UV cured elastomer having a Poisson's Ratio of about0.490 or less, and a shear modulus of between about 20 psi and about2900 psi. In some embodiments, the polymeric coating comprises athermoset, thermoplastic or UV cured elastomer having a

Poisson's Ratio of about 0.480 or less, and a shear modulus of betweenabout 20 psi and about 2900 psi.

Poisson's Ratio may be measured, for example, as described in ASTM D638.In certain embodiments, reference to a Poisson's Ratio means a Poisson'sRatio measured in accordance with ASTM D638. Shear modulus may bemeasured, for example, as described in ASTM E143. In certainembodiments, reference to a shear modulus means a shear modulus measuredin accordance with ASTM E143.

Young's modulus, also known as the elastic modulus or modulus ofelasticity, can be experimentally determined from the slope of astress-strain curve created during tensile tests (see ASTM D412)conducted on a sample of the material. The slope of the stress-straincurve at any point is the tangent modulus and the tangent modulus of theinitial, linear portion of the stress-strain curve is the Young'smodulus.

Bulk modulus of a polymer measures the polymer's resistance to uniformcompression and is defined as the ratio of the infinitesimal pressureincrease to the resulting relative decrease of the volume. One method ofmeasuring a material bulk modulus is to measure the material density andthe material sound speed in water (bulk modulus (K)=RhoC{circumflex over( )}2).

The polymer comprised by the polymeric coating should be selected suchthat it is hard enough not to suffer permanent plastic deformation atthe higher pressures and temperatures, which may degrade the acousticresponse enhancement. It is contemplated that polymers having a Shore Ahardness of between about 20 and about 95 will be most appropriate,although polymers having a hardness slightly above or below this rangeare also contemplated. In certain embodiments, the thermoset,thermoplastic or UV cured elastomer comprised by the polymeric coatinghas a Shore A hardness of between about 20 and about 95. In someembodiments, the polymeric coating comprises a thermoset, thermoplasticor UV cured elastomer having a Shore A hardness of between about 30 andabout 90, between about 30 and about 85, between about 35 and about 85,between about 40 and about 85, between about 45 and about 85, betweenabout 50 and about 85, or between about 55 and about 85. In someembodiments, the polymeric coating comprises a thermoset, thermoplasticor UV cured elastomer having a Shore A hardness of at least about 60.Shore A hardness can be measured, for example, according to ASTM D2240.In certain embodiments, reference to a Shore A hardness means a Shore Ahardness measured in accordance with ASTM D2240.

The exact nature of the thermoset, thermoplastic or UV cured elastomerincluded in the polymeric coating will be dependent on the end use ofthe coated optical fiber but the thermoset, thermoplastic or UV curedelastomer will in all cases meet the above-described Poisson's Ratio andshear modulus requirements and/or equivalent bulk modulus and Young'smodulus values to achieve the enhanced sensitivity. One skilled in theart provided with the required characteristics, could readily select anappropriate polymer. Examples of polymers that may be employed include,but are not limited to, certain Hytrel® polymers, various silicones,polyether thermoplastic elastomer (TPUs), polyester TPUs, andthermoplastic elastomers (TPEs) from Dow Chemical, BASF (for example,Elastolan) and Bayer Material Sciences (such as Desmopan® andTexin®—High-Tech Thermoplastic Polyurethanes), and UV cured polymersfrom Cytec Industries, Inc (Woodland Park, N.J.).

In certain embodiments in which the coated fiber is to be usedunderwater or in wet or damp environments, the elastomer should also behydrolytically stable. Examples of suitable hydrolytically stablepolymers include, but are not limited to, certain grades of Hytrel®polymers, various silicones, and polyether TPUs. Optical glass fibersensor reliability can be seriously degraded by direct contact withwater. The use of a hydrolytically stable polymer in accordance withcertain embodiments of the invention may, therefore, reduce the fiberfailure rate in wet or damp environments, such as well-boreenvironments.

In certain embodiments, a thermoset elastomer may be used. Thermosetelastomers, amongst others, may be particularly useful for hightemperature applications, for example, at operating temperatures up toabout 300° C. Non-limiting examples of thermoset elastomers for suchapplications include various silicones. Silicones suitable for coatingmaterials are known in the art and include, but are not limited to,peroxide cured silicones and platinum cured silicones, Suitablesilicones are commercially available from companies such as Momentive(Columbus, Ohio) and Dow Corning Corporation (Midland, Mich.).

In certain embodiments, a hybrid elastomer may be used. Hybridelastomers, amongst others, may be particularly useful for hightemperature applications, for example, at operating temperatures up toabout 300° C. Non-limiting examples of hybrid elastomers for suchapplications include fluoroelastomers (also known as rubberizedTeflons). Fluoroelastomers suitable for coating materials are known inthe art and include, but are not limited to, Kalrez from E.I. DuPont(Wilmington, Del.), and AFLAS from Asahi Glass Co Ltd, (Chiyoda, Tokyo).

In certain embodiments, a thermoplastic elastomer may be used.Thermoplastic elastomers, amongst others, are particularly useful wherethe end application does not require very high temperature stabilities.For example, a thermoplastic elastomer that is stable at operatingtemperatures up to about 150° C. In such applications, thermoplasticelastomers may provide better sensitivity than thermoset elastomers,although the latter are also suitable for use at these temperatures. Anon-limiting example of a thermoplastic elastomer for such applicationsis a polyester-polyether copolymer, such as a Hytrel® polymer. Examplesof suitable Hytrel® polymers include Hytrel® 3078, Hytrel® G3548L,Hytrel® G4078W, Hytrel® 4056, Hytrel® 4069 and Hytrel® 4556.

In certain embodiments, the polymer is extrudable in order to facilitatecoating of the optical fiber, although other methods of applying thepolymer are also contemplated. Examples of suitable extrudableelastomers include, but are not limited to, certain Hytrel® polymers,various silicones, polyether thermoplastic elastomer (TPUs), polyesterTPUs, and thermoplastic elastomers (TPEs) from Dow Chemical, BASF (forexample, Elastolan) and Bayer Material Sciences (such as Desmopan® andTexin®—High-Tech Thermoplastic Polyurethanes).

In certain embodiments, the polymeric coating may be selected to besubstantially transparent. Such transparency will allow for visualinspection of the fiber for breaks or anomalies and, when the fibercomprises FBGs, for the location and/or integrity of the FBGs. Varioussilicones are available that are substantially transparent.

In certain embodiments, the polymeric coating may be coloured to allowfor easy identification of the coated fibers. A dye may be used thatwould maintain some transparency or a pigment may be added that wouldsubstantially eliminate the base polymer transparency.

The final thickness of the polymer coating on the optical fiber will bedependent on the initial diameter of the optical fiber employed and, insome cases, also on the end use of the coated fiber including whether itwill be incorporated into a sub-assembly such as a cable or sensorarray. Appropriate coating thicknesses for a given fiber or applicationcan be determined by one skilled in the art. Typically, the finaldiameter of the coated fiber will be between about 100 um and about 4000um, although final diameters of up to about 10,000 um are contemplatedin certain embodiments, for example, those utilizing plastic opticalfibers. For example, the outer diameter of the coated fiber may be fromabout 100 um, 150 um, 200 um, 250 um, 300 um, 350 um, 400 um or 450 umto about 4000 um, 3500 um, 3000 um or 2500 um. Exemplary ranges of outerdiameters for the coated optical fiber include, but are not limited to,between about 500 um and about 4000 um, between about 500 um and about3500 um, between about 500 um and about 3000 um, between about 500 umand about 2500 um, between about 500 um and about 2000 um, between about500 um and about 1500 um, between about 750 um and about 2000 um, andbetween about 1000 um and about 2000 um. In certain embodiments, thefinal diameter of the coated optical fiber may be between about 900 umand about 2000 um, for example, about 1500 um.

The polymer coated optical fibers described herein may be manufacturedaccording to known techniques. Typically, the polymer coating will beapplied to the fiber as a concentric coating by techniques such asextrusion, pultruding or molding using conventional equipment. In someembodiments, the polymer coating may be extruded onto the fiber usingconventional extruders suitable for extrusion of thermoplastic orthermoset elastomers, or may be applied by industry known processes forapplying UV cured polymers to fibers and/or conductors. One or morepost- or in-process elevated temperature curing steps and/or coolingsteps may be included if necessary. One or more UV curing steps may alsobe included in some embodiments.

Optical fibers coated as described above have improved acoustic sensingproperties under condition of elevated pressure and/or temperatures,such as enhanced acoustic sensitivity and/or a reduced loss in acousticsensitivity. In certain embodiments for example, the coated opticalfibers as described herein show an enhanced Sensitivity Scale Factor ofbetween about 5 dB and about 60 dB over bare fiber in a similarconfiguration, for example between about 5 dB and about 55 dB, orbetween above 5 dB or about 50 dB, over bare fiber in a similarconfiguration. In certain embodiments, the polymer coated optical fibersdescribed herein also have an improved durability, making themparticularly suited for use in harsh conditions, such as downhole anddeep well applications.

The improved sensing properties of the polymer coated optical fibersallow for their use as acoustic sensors in a variety of applicationsincluding, for example, geological, security, military, aerospace,marine, and oil and gas applications. In particular, the polymer coatedfibers may find application in structural monitoring systems includingfor offshore drilling operations, nuclear reactor performance monitoringsystems, seismic sensor systems, pipeline monitoring/intrusion detectionand as downhole sensors in the oil and gas industry.

In certain embodiments, the invention relates to the use of the polymercoated fibers in fiber optic sensors for application in the geologicalexploration industry, for example, to monitor seismic return signalsfrom external geophysical sound pulse sources. The sensors may bedeployed subsurface or ocean bottom as line arrays. In certainembodiments, the sensors may be used in hot, subsurface environments todetect hydrocarbon locations the earth's strata. In this context, theimproved acoustic properties of the polymer coated optical fibers mayallow the detection of weaker seismic signals which enhance the seismicsurvey coverage range, and at higher temperatures and static pressuresthan other types of fiber optic sensors.

In certain embodiments, the invention relates to the use of the polymercoated fibers in fiber optic sensors for application in nuclear reactormonitoring, for example, to monitor reactor integrity, detect leaks, andthe like. The sensors may be deployed inside or outside a channel (forexample, inside or strapped to the outside of a casing). In certainembodiments, the sensors may be used in hot environments (for example,to detect gas or liquid leaks around the casings).

In certain embodiments, the invention relates to the use of the polymercoated fibers in fiber optic sensors for application in nuclearexplosion monitoring. The coated optical fibers may allow for detectionof fainter explosions, for example at a greater distance, due to theenhanced sensitivity.

In certain embodiments, the invention relates to the use of the polymercoated fibers in fiber optic sensors for application in seismicmonitoring where the sensor can detect and localize earthquake activity.In some embodiments, the use of the coated optical fibers for detectionof earthquake precursors for public alarm systems is contemplated, forexample, through the deployment of a series of single coated fibers,each down a very small bore hole, along locations adjacent to a knownfault line.

In certain embodiments, the invention relates to the use of the polymercoated fibers in fiber optic sensors for application in the aboveground, surface, subsurface or underwater security monitoring. Forexample, the enhanced sensitivity of the coated fibers may allow forperimeter defence systems which can detect, classify, and localize athreat by measuring the spectral and temporal properties of sound waves,seismic ground vibrations, and/or airborne intruder sounds.

In certain embodiments, the invention relates to the use of the polymercoated fibers in fiber optic sensors for application in the oil and gasindustry, for example, to monitor well integrity, detect pipeline leaks,monitor horizontal well production, monitor fracking processes, and thelike. The sensors may be deployed inside or outside a channel (forexample, inside or strapped to the outside of a casing). In certainembodiments, the sensors may be used in hot, deep oil well casings (forexample, to detect gas or liquid leaks around the downhole well casingsand concrete grouting), to detect reflections of sound waves directedinto the earth's strata in the search for geological deposits of oil andgas, or to detect gas or oil leaks adjacent to a well bore. In thiscontext, the improved acoustic properties of the polymer coated opticalfibers may allow the detection of hydrocarbon reflections at much largerdistances from the well bore containing the sensor and/or at highertemperatures than other types of fiber optic sensors without heatsensitive degradation associated with electrical downhole sensors orfiber sensors with low temperature coatings, and/or the detection andlocation of low level sound emanating from gas leaks outside the wellcasing.

Sensor Systems

Certain embodiments of the invention relate to sensor systems comprisingthe polymer coated optical fiber. The polymer coated optical fiber maybe incorporated into a sensor array or assembly and/or wound around ahollow or solid mandrel, or incorporated as part of a cable assemblywith other sensing and non-sensing components. For high pressureapplications, sensor arrays or assemblies that do not include a mandrel,or which include a pressure-insensitive mandrel, are preferred. Varioussensor arrays and assemblies are known in the art and include thosedescribed in U.S. Pat. No. 7,224,872, and U.S. Patent ApplicationPublication Nos. 2012/0227504 and 2013/0167628. In certain embodiments,a sensor array, or hollow or solid fiber-wrapped mandrel may furthercomprise an outer protective jacket, for example, an acousticallytransparent metal or polymer jacket. In certain embodiments, the polymercoated optical fiber is used in the sensor system without any additionalcoatings or jackets.

Typically, the sensor system will further comprise a light or lasersource, a detector and a signal processor. The sensor system mayoptionally include other sensing components.

In certain embodiments, the sensor system comprises coated opticalfibers that include groups of FBGs located along the length of thefiber.

FIG. 1A is a block diagram of an example of a system that uses opticalinterferometry for fiber optic sensing applications. Opticalinterferometry is a technique in which a light pulse that is emitted byan optical source is split into two separate pulses: a sensing pulse anda reference pulse. The optical source may be a coherent optical source,such as a laser. When optical interferometry is used for fiber opticsensing applications, the sensing and reference pulses are at leastpartially reflected back towards an optical receiver. Accordingly, inFIG. 1A, an optical source 101 emits a light pulse on to optical fiber112. The light pulse passes through an optical coupler 109 and is splitinto the sensing and reference pulses, which are transmitted along twodifferent optical fiber segments. The reference pulse is delayed usingan optical delay line 105, and both the sensing and delayed referencepulses are reflected back to the optical coupler 109 and directed toanother optical fiber segment that comprises a first pair of fiber Bragggratings (“FBGs”) via an optical circulator 107. The first pair of FBGscomprises first and second FBGs 114 a,b (generally, “FBGs 114”). Thefirst and second FBGs 114 a,b are separated by a certain segment 116 ofthe optical fiber 112 (“fiber segment 116”). The light pulse has awavelength identical or very close to the center wavelength of the FBGs114, which is the wavelength of light the FBGs 114 are designed topartially reflect. The sensing and delayed reference pulses areaccordingly each partially reflected by the FBGs 114 a,b and return tothe optical circulator 107, which directs them to the optical receiver103. The optical delay line 105 is configured to delay the referencepulse such that the delayed reference pulse that reflects off the firstFBG 114 a (hereinafter the “reflected, delayed reference pulse”) arrivesat the optical receiver 103 simultaneously with the sensing pulse thatreflects off the second FBG 114 b (hereinafter the “reflected sensingpulse”), which permits optical interference to occur. While the FBGs 114are used as partial reflectors of light pulses in the depictedembodiment, in alternative embodiments (not depicted) different types ofpartial reflectors may be used.

FIG. 1C depicts how the FBGs 114 reflect the light pulse, according toanother embodiment in which the optical fiber 112 comprises a third FBG114 c. In FIG. 1C, the second FBG 114 b is equidistant from each of thefirst and third FBGs 114 a,c when the fiber 112 is not strained. Thelight pulse is propagating along the fiber 112 and encounters threedifferent FBGs 114, with each of the FBGs 114 reflecting a portion 115of the pulse back towards the optical receiver 101. In embodimentscomprising three or more FBGs 114, the portions of the sensing anddelayed reference pulses not reflected by the first and second FBGs 114a,b can reflect off the third FBG 114 c and any subsequent FBGs 114,resulting in interferometry that can be used to detect strain along thefiber 112 occurring further from the optical source 101 than the secondFBG 114 b. For example, in the embodiment of FIG. 1C, a portion of thesensing pulse not reflected by the first and second FBGs 114 a,b canreflect off the third FBG 114 c and a portion of the delayed referencepulse not reflected by the first FBG 114 a can reflect off the secondFBG 114 b, and these reflected pulses can interfere with each at theoptical receiver 103.

Any changes to the optical path length of the fiber segment 116 resultin a corresponding phase difference between the reflected, delayedreference pulse and the reflected sensing pulse at the optical receiver103; however, these two pulses are superimposed at the optical receiver103 and the phase difference between them therefore cannot be directlymeasured. Instead, the phase of the signal measured at the opticalreceiver 103 is determined relative to the phase of the referencesignal, whose phase is known because the optical source 101phase-modulates it by subjecting it to a time-dependent 0-2 π phasesweep. The relationship between the optical path of the fiber segment116 and that phase difference (θ) is as follows:

$\theta = \frac{2\pi\;{nL}}{\lambda}$where n is the index of refraction of the optical fiber; L is theoptical path length of the fiber segment 116; and λ is the wavelength ofthe optical pulses. A change in L is caused by the fiber experiencinglongitudinal strain induced by energy being transferred into the fiber.The source of this energy may be, for example, an object outside of thefiber experiencing dynamic strain, undergoing vibration, or emittingacoustics. As used herein, “dynamic strain”, refers to strain thatchanges over time. Dynamic strain that has a frequency of between about5 Hz and about 20 Hz is referred to by persons skilled in the art as“vibration”, dynamic strain that has a frequency of greater than about20 Hz is referred to by persons skilled in the art as “acoustics”, anddynamic strain dynamic strain that changes at a rate of <1 Hz, such asat 500 μHz, is referred to as “sub-Hz strain”.

One conventional way of determining ΔnL is by using what is broadlyreferred to as distributed acoustic sensing (“DAS”). DAS involves layingthe fiber 112 through or near a region of interest and then sending acoherent laser pulse along the fiber 112. As shown in FIG. 1D, the laserpulse interacts with impurities 113 in the fiber 112, which results inscattered laser light 117 because of Rayleigh scattering. Vibration oracoustics emanating from the region of interest results in a certainlength of the fiber becoming strained, and the optical path change alongthat length varies directly with the magnitude of that strain. Some ofthe scattered laser light 117 is back scattered along the fiber 112 andis directed towards the optical receiver 103, and depending on theamount of time required for the scattered light 117 to reach thereceiver and the phase of the scattered light 117 as determined at thereceiver, the location and magnitude of the vibration or acoustics canbe estimated. DAS relies on interferometry using the reflected light toestimate the strain the fiber experiences. The amount of light that isreflected is relatively low because it is a subset of the scatteredlight 117. Consequently, and as evidenced by comparing FIGS. 1C and 1D,Rayleigh scattering transmits significantly less light back towards theoptical source 101 than using the FBGs 114. DAS accordingly usesRayleigh scattering to estimate the magnitude, with respect to time, ofthe strain experienced by the fiber during an interrogation time window,which is a proxy for the magnitude of the vibration or acousticsemanating from the region of interest. In certain embodiments, thesensor system is configured to utilize DAS.

In certain embodiments, the sensor system may be configured to measuredynamic strain by using interferometry resulting from laser lightreflected by FBGs 114 that are added to the fiber 112 and that aredesigned to reflect significantly more of the light than is reflected asa result of Rayleigh scattering. This contrasts with an alternative useof FBGs 114 in which the center wavelengths of the FBGs 114 aremonitored to detect any changes that may result to it in response tostrain.

In the depicted embodiments, groups of the FBGs 114 are located alongthe fiber 112. A typical FBG can have a reflectivity rating of 2% or 5%.In certain embodiments, the use of FBG-based interferometry to measuredynamic strain can offer several advantages over DAS, such as increasedaccuracy, precision, range, and response time.

Referring now to FIG. 1B, there is shown one embodiment of a system 100for detecting dynamic strain of a conduit. The system 100 comprises theoptical fiber 112, an interrogator 106 optically coupled to the opticalfiber 112, and a signal processing device 118 that is communicative withthe interrogator 106. While not shown in FIG. 1B, within theinterrogator 106 are the optical source 101, optical receiver 103,optical delay line 105, and optical circulator 107.

The optical fiber 112 comprises one or more fiber optic strands, each ofwhich is made from quartz glass (amorphous SiO₂). The fiber opticstrands are doped with a rare earth compound, such as germanium,praseodymium, or erbium oxides) to alter their refractive indices,although in alternative embodiments the fiber optic strands may not bedoped. Single mode and multimode optical strands of fiber arecommercially available from, for example, Corning® Optical Fiber.Example optical fibers include ClearCurve™ fibers (bend insensitive),SMF28 series single mode fibers such as SMF-28 ULL fibers or SMF-28efibers, and InfiniCor® series multimode fibers.

Located on the optical fiber 112 are the FBGs 114 separated by the fibersegment 116, as discussed in respect of FIG. 1A above. Each of the FBGs114 a,b is tuned to reflect a substantially identical center wavelengthof light; for example, typical FBGs 114 are tuned to reflect light inthe 1.000 to 2.000 nm wavelength range. The length of the fiber segment116 varies in response to dynamic strain that the optical fiber 112experiences. While FIG. 1B shows only the one pair of FBGs 114 a,b, inalternative embodiments (not depicted) any number of pairs of FBGs 114may be on the fiber 112, and time division multiplexing (TDM) (andoptionally wavelength division multiplexing (WDM)) may be used tosimultaneously obtain measurements from them. If two or more pairs ofFBGs 114 are used, any one of the pairs may be tuned to reflect adifferent center wavelength than any other of the pairs; in that exampleembodiment, WDM may be used in order to transmit and to receive lightfrom the different pairs of FBGs 114, effectively extending the numberof FBG pairs that can be used in series along the optical fiber 112 byreducing the effect of optical loss that otherwise would have resultedfrom light reflecting from the FBGs 114 located on the fiber 112 nearerto the optical source 101. When different pairs of the FBGs 114 are nottuned to different center wavelengths, TDM is sufficient.

The interrogator 106 emits laser light with a wavelength selected to beidentical or sufficiently near the center wavelength of the FBGs 114that each of the FBGs 114 partially reflects the light back towards theinterrogator 106. The timing of the successively transmitted lightpulses is such that the light pulses reflected by the first and secondFBGs 114 a,b interfere with each other at the interrogator 106, and theoptical receiver 103 records the resulting interference signal; the useof sensing and reference pulses to cause this interference is discussedin more detail with respect to FIG. 1A, above. The strain that the fibersegment 116 experiences alters the optical path length between the twoFBGs 114 and thus causes a phase difference to arise between the twointerfering pulses. The resultant optical power at the optical receiver103 can be used to determine this phase difference as described abovewith respect to FIG. 1A. Consequently, the interference pattern that theinterrogator 106 records varies with the strain the fiber segment 116 isexperiencing, which allows the interrogator 106 to estimate the strainthe fiber segment 116 experiences from the received optical power.Suitable interrogators 106 are commercially available and include anOptiphase™ TDI7000. The interrogator 106 digitizes the phase difference(“output signal”) whose magnitude and frequency vary directly with themagnitude and frequency of the dynamic strain the fiber segment 116experiences.

The signal processing device 118 is communicatively coupled to theinterrogator 106 to receive the output signal. The signal processingdevice 108 includes a processor 102 and a non-transitory computerreadable medium 104 that are communicatively coupled to each other, andan input device 110 and a display 108 for interacting with the processor102. The computer readable medium 104 has encoded on it statements andinstructions to cause the processor 102 to perform any suitable signalprocessing methods to the output signal. For example, if the fibersegment 116 is laid adjacent a region of interest that is simultaneouslyexperiencing vibration at a rate under 20 Hz and acoustics at a rateover 20 Hz, the fiber segment 116 will experience similar strain and theoutput signal will comprise a superposition of signals representative ofthat vibration and those acoustics. The processor 102 may apply a lowpass filter with a cutoff frequency of 20 Hz to the output signal toisolate the vibration portion of the output signal from the acousticsportion of the output signal. Analogously, to isolate the acousticsportion of the output signal from the vibration portion, the processor102 may apply a high pass filter with a cutoff frequency of 20 Hz. Theprocessor 102 may also apply more complex signal processing methods tothe output signal; example methods include those described in theInternational (PCT) application PCT/CA2012/000018 (publication number WO2013/102252), the entirety of which is hereby incorporated by reference.

In certain embodiments, the sensor system is a sensor system for use inoil and gas applications. For example, the sensor system may beconfigured for deployment inside or outside a channel for detectingfluid migration in an oil or gas well or in a pipeline, for monitoringwell integrity, monitoring horizontal well production or monitoringfracking processes.

Fluid migration in oil or gas wells is generally understood to meaningress or egress of a fluid along a vertical depth of an oil or gaswell, including movement of a fluid behind or external to a productioncasing of a wellbore. The fluid may include gas or liquid hydrocarbons,including oil, as well as water, steam, or a combination thereof. Avariety of compounds may be found in a leaking well, including methane,pentanes, hexanes, octanes, ethane, sulphides, sulphur dioxide, sulphur,petroleum hydrocarbons, oils or greases, as well as other odour-causingcompounds. Some compounds may be soluble in water, to varying degrees,and represent potential contaminants in ground or surface water. Anysort of aberrant or undesired fluid migration is considered a leak and asensor system, such as the one described herein, may be used to detectsuch leaks in order to facilitate repair of the leak. Such leaks canoccur in producing wells or in abandoned wells, or wells whereproduction has been suspended.

Suitable apparatus for deploying sensors in downhole applications areknown in the art. FIG. 2 illustrates a sensing system comprising apolymer coated optical fiber as described herein deployed in an oil orgas well, or similar well, such as a geothermal well. In FIG. 2, aflexible fiber optic assembly 202 comprising at least one polymer coatedoptical fiber is deployed in the well bore 204. The fiber optic assemblyincludes a weight 206 coupled to the distal end of the assembly 202. Thefiber optic assembly 202 is deployed into the well bore from a spool 208that also stores the assembly 202 in coiled form when not in use. Amotor (not shown) may be operationally coupled to the spool 208 and canbe operated to deploy and retract the assembly 202. The fiber opticassembly 202 is in communication with optical signal processingequipment 210. Optical signal processing equipment 210 may includevarious electronics and optical components necessary to provide a lightbeam down the optical fiber, and to analyze the raw measurement datafrom the fiber optic assembly 202 and to convert these data into a formrepresentative of the sensed acoustic signals that may be displayed,printed or further analyzed. Optical signal processing equipment 210 mayoptionally be configured to communicate with additional processingequipment, such as a computer or computer network. The communicationsmay occur either over wires or other hard connections, including opticalnetworks, or the communications may occur wirelessly.

The spool 208 and optical signal processing equipment 210 may optionallybe housed on a trailer or other suitable vehicle such that the fiberoptic assembly 202, spool 208 and optical signal processing equipment210 form a mobile apparatus. Alternatively, the fiber optic assembly202, spool 208 and optical signal processing equipment 210 can beconfigured for permanent or semi-permanent operation at a well boresite.

In FIG. 2, the coated optical fiber comprised by fiber optic assembly202 may comprise FBGs each tuned to reflect an identical wavelength oflight, and optical signal processing equipment 210 may comprise aninterrogator optically coupled to the optical fiber assembly 202, and asignal processing device (as depicted in FIG. 1 as 106 and 118). Theinterrogator comprising a laser source for sending pulses of laser lightalong the fiber optic assembly 202 and a photodetector for detectinglight that is reflected by the FBGs, and the signal processing deviceincluding a processor and a non-transitory computer readable medium thatare communicatively coupled to each other, and an input device and adisplay for interacting with the signal processing device (as depictedin FIG. 1 as 108, 104, 102 and 110).

Methods of Manufacture

Certain embodiments of the invention relate to methods of manufacturinga coated optical fiber suitable for use in high pressure and/or hightemperature operating environments, which includes selecting athermoplastic, thermoset or UV cured elastomer having a Poisson's Ratiobetween about 0.350 and about 0.4995, and a shear modulus of betweenabout 20 psi and about 2900 psi, and concentrically coating a glass orplastic optical fiber with the selected thermoplastic, thermoset or UVcured elastomer. The thermoplastic, thermoset or UV cured elastomer maybe coated onto the fiber by extrusion, pultruding, molding or the like.

In certain embodiments, the thermoplastic, thermoset or UV curedelastomer polymer may be extruded onto the fiber. In some embodiments,the polymer coating may be extruded onto the fiber using conventionalextruders suitable for extrusion of thermoplastic or thermosetelastomers. One or more post- or in-process elevated temperature or UVcuring steps and/or cooling steps may be included if necessary.

In some embodiments, for coating with a UV cured polymer, fiber may bepulled through a bath of the polymer to create a wet, viscous cone shapeof material on the fiber at a rate that produces the desired coatingdiameter. The uncured polymer on the fiber is then exposed to a UV lightsource that rapidly cures the polymer creating a solid coating on thefiber at the desired diameter. Adjustment of the final coating diametercan be obtained by changing the speed at which the fiber is pulledthrough the liquid bath. The higher the viscosity or the slower thefiber is pulled through the bath, the larger the coating finisheddiameter.

In some embodiments in which a thermoplastic or thermoset elastomer isextruded over the optical fiber, the extrusion process tension may becontrolled to be low to moderate (for example, 20 to 150 gm) and to beconstant (for example, +/−5 to 20 gm) depending upon the fiber andapplication. One skilled in the art will appreciate that additional carewill need to be taken when coating fibers including FBGs, which cancause irregularities in the diameter of the fiber. In general, thediameter variation of the fiber with FBGs needs to be limited so thatanomalies (lumps) over splices or recoated FBGs are small relative tothe nominal diameter of the fiber. For larger fibers (for example, 125um cladding and dual acrylate coatings to 245 um) the lump diameterdivided by the nominal fiber diameter is typically kept to less than 1.2For smaller fibers, the ratio may increase to as much as 1.35 forexample. The extruder tooling and fiber handling equipment should beselected to accommodate the FBG lumps and maintain concentricity of thecoating while also coating over the lumps without large tensionvariation.

In some embodiments in which a UV cured elastomer is coated over theoptical fiber, the process of pulling the fiber through a liquid viscousbath must maintain a tension controlled to be low to moderate (forexample, 20 to 150 gm) and to be constant (for example, +/−5 to 20 gm)depending upon the fiber and application. This coating process is lesssensitive to fiber diameter variation but one skilled in the art willappreciate that additional care may still need to be taken when coatingfibers including FBGs. Accordingly, the tooling and fiber handlingequipment should be selected to accommodate the FBG lumps and maintainconcentricity of the coating while also coating over the lumps withoutlarge tension variation.

In some embodiments, the thermoset, thermoplastic or UV cured elastomeralso has a Shore A hardness of between about 20 and about 95. In someembodiments, the thermoplastic or thermoset elastomer may be a Hytrel®polymer or a silicone.

In some embodiments, the optical fiber comprises an acrylate orpolyimide primary coating and the selected thermoplastic or thermosetelastomer or UV-cured polymer is extruded or otherwise applied over theprimary coating. In some embodiments, the optical fiber may have adiameter of between about 50 um and about 200 um. In some embodiments,the optical fiber comprises FBGs written onto or spliced into the fiber.

In some embodiments, the selected thermoplastic or thermoset elastomeris extruded over the optical fiber to a final diameter of between about100 um and about 4000 um, for example, between about 500 um and about4000 um, between about 500 um and about 2500 um, or about 1500 um.

In some embodiments, the fiber is pulled thru a polymer bath and UVcured to create a final diameter of between about 100 um and about 4000um, for example, between about 500 um and about 4000 um, between about500 um and about 2500 um, or about 1500 um.

In certain embodiments, the coating on the fiber facilitates the use ofautomatic sensor manufacturing techniques through the increasedrobustness of the coated fiber, which facilitates the use of sensorspooling and tension monitoring required in automatic sensor windingmachines, and minimizes touch labor requirements which are prevalent incurrent fiber optic sensor manufacturing. For example, the coated fibermanufacturing process using a Hytrel® 3078 or silicone SE9058 coatedfiber as described in the Examples herein has demonstrated thefabrication of over 30 sensors in a single continuous array string inapproximately 1/10 the labor time of single sensor manufacturingtechniques.

To gain a better understanding of the invention described herein, thefollowing examples are set forth. It will be understood that theseexamples are intended to describe illustrative embodiments of theinvention and are not intended to limit the scope of the invention inany way.

EXAMPLES Example 1: Preparation of Coated Fibers

The following coated fibers were prepared. The fibers were allcommercially available glass/fused silica quartz fibers.

-   -   80 um glass fiber with acrylate coating and Hytrel® 3078        buffering to 1500 um.    -   80 um glass fiber with high temperature acrylate coating and        Hytrel® 3078 buffering to 1500 um.    -   125 um glass fiber with acrylate coating and Hytrel® 3078        buffering to 1500 um.    -   125 um glass fiber with high temperature acrylate coating and        Hytrel® 3078 buffering to 1500 um.    -   80 um glass fiber with acrylate coating and SE9058 buffering to        1500 um.    -   80 um glass fiber with high temperature acrylate coating and        SE9058 buffering to 1500 um.    -   125 um glass fiber with acrylate coating and SE9058 buffering to        1500 um.    -   125 um glass fiber with high temperature acrylate coating and        SE9058 buffering to 1500 um.    -   Both 80 um and 125 um glass fibers with acrylate, high        temperature acrylate or polyimide coatings all with FBGs        pre-written on, or spliced into, the fibers coated to 1500 um        with Hytrel® 3078 or silicone SE9058.    -   80 um glass fiber with acrylate coating and Cytec Industries 80A        Radcure polymer buffering to 1500 um.

The fiber diameter and coating thickness were selected based on analysisand prior work that indicated performance increased with coatingthickness but at a decreasing rate, and that 80 um fiber has increasedperformance compared to 125 um fiber.

Hytrel® were extruded onto the fiber using commercially available andconventional thermoplastic extruders. Silicone was extruded onto thefiber using commercially available silicone thermoset extruders.

The Radcure polymer was coated onto the fiber using a conventional UVcurable polymer coating process in which the fiber is pulled through aviscous liquid bath of the polymer to create a cone shape of polymer onthe fiber, and subsequently exposed to a UV light source making a solidpolymer on the fiber of the desired diameter.

Selected properties for the Hytrel® 3078, silicone SE9058 and UV curedpolymer used as coatings are provided in Table 1.

TABLE 1 Selected Properties of Polymers Approx. Shear Density/ Poisson'sMaximum Modulus/ Hardness/ Polymer lbs in⁻³ Ratio Temp/° C. psi Shore AHytrel ® 3078 0.0386 0.45 150 1358.86 80 Silicone 0.0466 0.48 300 107.2860 SE9058* 80A Radcure 0.0390 0.4995 120 772.40 80 polymer *Press cure

Example 2: Testing of Coated Fibers

The Hytrel® and Radcure polymer coated fibers were each tested foracoustic sensitivity in a static calibration chamber. As the coatingenhances both the static and dynamic strain in the cladded core of theoptical fiber, the use of a static calibration test can greatly simplifyobtaining a calibration of the acoustic sensitivity (commonly calledSensor Scale Factor). Accordingly, measuring the change in the fiberstrain in a relatively simple static pressure chamber avoids thecomplexity and higher costs of conducting an acoustic sensor calibrationin an anechoic chamber.

Briefly, the test chamber was constructed to accept wound optical fiberover a rigid mandrel to create a sensor. The chamber included acontrolled water inlet and a controlled water outlet, such that waterflow into and out of the chamber could be regulated allowing thecreation of a balanced pressure within the chamber. Water flow throughthe system maintained the water temperature. The chamber was alsooutfitted with means to measure the chamber temperature, as well asmeans to measure and control the chamber pressure.

The coated fiber sensor was positioned inside the chamber and lockedinto place to create a sealed chamber. Both ends of the fiber wererouted so they exited the chamber through pressure sealing fittings. Thefiber was connected to a single channel interrogator.

The chamber was continuously filled with water to evacuate any air thatmay be trapped in the chamber and to allow the chamber temperature tonormalize. Upon reaching steady-state pressure and temperature, a staticcalibration test was conducted measuring the performance of theparticular coated fiber in the chamber.

The pressure inside the chamber was then increased and the coated fiberperformance was re-measured. This process was repeated for multiplepressures, measuring the fiber performance at each pressure.

The results are shown in FIGS. 4A and B, which provides a comparison ofmeasured acoustic sensitivities for the Hytrel® and UV cured polymercoated fibers together with analytical model-predicted acousticsensitivity of bare fiber. The Hytrel® fiber coating (H1) measurementsare seen to agree very closely with the Scale Factor prediction model(FIG. 4A). The UV cured polymer fiber coating (P1) measurements did notagree as closely with the predictions (FIG. 4A). This may be due toerrors in the assumed material properties for P1. The Hytrel® coatedfiber is shown to be over 50 dB more sensitive than the predictedsensitivity of a bare 80 μm fiber (FIGS. 4A and B), whereas the UV curedpolymer coated fiber is shown to be approximately 25 dB more sensitive.

The Hytrel® and silicone SE9058 coated fibers were tested in downholesensors and shown to retain good sensitivity under high temperature andpressure operating conditions.

The disclosures of all patents, patent applications, publications anddatabase entries referenced in this specification are herebyspecifically incorporated by reference in their entirety to the sameextent as if each such individual patent, patent application,publication and database entry were specifically and individuallyindicated to be incorporated by reference.

Although the invention has been described with reference to certainspecific embodiments, various modifications thereof will be apparent tothose skilled in the art without departing from the spirit and scope ofthe invention. All such modifications as would be apparent to oneskilled in the art are intended to be included within the scope of thefollowing claims.

We claim:
 1. A sensor system comprising: a coated optical fiber, whereinthe coated optical fiber comprises an optical fiber having a polymericcoating, the polymeric coating comprising a thermoset, thermoplastic orUV cured elastomer having a Poisson's Ratio of between about 0.350 andabout 0.4995, and a shear modulus of between about 20 psi and about 2900psi; a light source; a detector; and a signal processor.
 2. The sensorsystem according to claim 1, wherein the thermoset, thermoplastic or UVcured elastomer has a Shore A hardness of between about 20 and about 95.3. The sensor system according to claim 1, wherein the Poisson's Ratiois less than about 0.490.
 4. The sensor system according to claim 1,wherein the polymeric coating comprises a thermoset elastomer that isstable at operating temperatures up to about 300° C.
 5. The sensorsystem according to claim 4, wherein the thermoset elastomer is asilicone.
 6. The sensor system according to claim 1, wherein thepolymeric coating comprises a thermoplastic or UV cured elastomer thatis stable at operating temperatures up to about 150° C.
 7. The sensorsystem according to claim 6, wherein the thermoplastic elastomer is apolyester-polyether copolymer.
 8. The sensor system according to claim7, wherein the thermoplastic elastomer is Hytrel®
 3078. 9. The sensorsystem according to claim 6, wherein the UV cured elastomer is analiphatic urethane acrylate, aromatic urethane acrylate, an epoxyacrylate, an acrylic acrylate, or a combination thereof.
 10. The sensorsystem according to claim 1, wherein the coated fiber shows an increasedSensitivity Scale Factor of between about 5 dB and about 60 dB over barefiber.
 11. The sensor system according to claim 1, for use in detectingacoustic changes in a channel.
 12. The sensor system according to claim1, for use in geological exploration.
 13. The sensor system according toclaim 1, for use in seismic monitoring.
 14. The sensor system accordingto claim 1, for use in security monitoring.
 15. The sensor systemaccording to claim 1, for use in nuclear explosion monitoring or leakdetection.
 16. The sensor system according to claim 1, for use intemperature measurement.
 17. A method of producing a coated opticalfiber having an increased Sensitivity Scale Factor of between about 5 dBand about 60 dB over bare fiber, the method comprising coating anoptical fiber with a thermoset, thermoplastic or UV cured elastomer, theelastomer having a Poisson's Ratio of between about 0.350 and about0.4995, and a shear modulus of between about 20 psi and about 2900 psi.18. A system for detecting acoustic changes in a channel, the systemcomprising: at least one coated optical fiber; an interrogator opticallycoupled to the coated optical fiber; and a signal processing device incommunication with the interrogator, wherein the coated optical fibercomprises an optical fiber having a polymeric coating, the polymericcoating comprising a thermoset, thermoplastic or UV cured elastomerhaving a Poisson's Ratio of between about 0.350 and about 0.4995, and ashear modulus of between about 20 psi and about 2900 psi.
 19. The systemaccording to claim 18, wherein the channel is a pipeline or a well-borecasing.
 20. The system according to claim 19, wherein the acousticchanges are indicative of a leak in the pipeline or the well-borecasing.